Method and apparatus for casting steel ingots



June' 22,1926. 1,589,730

- E. H. WILLIAMS n METHOD AND APPARATUS FOR CASTING STEEL INGOTS FiledJan. 24, 1921 2 Sheets-Sheet 1 24 y ;f 7 d!! y 10 L f7' "HH.., .""WHIHWW"UHHHMH "umh".I 76 Z3 f4 J1 z5 I I .I I

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E. H. WILLIAMS METHOD AND APPARATUS FOR lCASTING STEEL INGOTS 2Sheets-Sheet 2 Filed Jan. l 24. 1921 www1/Wam@ @513 4m atto/heg iPatented l.lune 22, 1926.

UNITED STATES ri-ifislv'rv oI-Flclaf EDWARD H. WILLTAMS, OF SHARON,PENNSYLVANIA, ASSIGNOB TO VALLEY MOULD & IRON CORPORATION, OFSHARPSVILLE, PENNSYLVANIA, A CORPORATION OF NEW YORK.

METHOD AND APPARATUS FOR CASTING STEEL INGOTS.

Application filed January 24, 1921. Serial No. 439,357.

This invention relates broadly to metallurgy and more specially-to amethod and apparatus for casting horizontal ingots from dead meltedsteel.

The principal object of the present in vention is the method andapparatus of casting horizontal ingots from dead melted steel by j)roviding a hot member in contact with one end of the ingot duringpouring and cooling.

A still further object of thel present `invention is Vthe method andapparatus of casting` steel ingo\ts from dead melted steel wherein aheated runner is provided adjacent one end of the ingot in such man neras to prevent chilling' of one end of the ingot during pouring, therebypermitting molten steel to he suppliedV until the steel is 'set thuspreventing formation of pipes or cavities in the ingot. j Y

n, still further object of the present invention is a method `andapparatus of castingrstcel ingots in horizontal molds by proriding arunneradjacent one end of the mold and which runner is provided with aplurality of openings arranged in such manner that` substantially thesame volume of steel issues from the upper and lower openings into themold during the pouring operation.: i

n, still further and important object of thel present invention isthemethod and apparatus of Acasting Vhorizontal steelingots which comprisesarranging runner openings adjacent one end of the matrix end'of the moldin such manner that a plurality of in'- lcts lead from the runner to thematrix'and with the upper inlets being of larger crosssectiona-l areathan the lower inlets.

-instill further and important object of the present invention is aningot mold for casting horizontal steel ingots, which mold is providedwith an opening adjacent one end thereof adaptedto receive a runner tileof such size vas to comprise the majority of the end wall of the matrixportion of the mold when the runner tile is in position.

A still further and primary object of the present invention is anarticle'of manufacture comprising a runner tile for use in castinghorizontal ingots, which runner tile 1s of relatively wide width. toprevent chilling of the steel adj acent'the runner tile dur* ing thepouring operation'and wherein said runner tile is adapted to bestandardized so that said tile may be interchangeableV with any one of aplurality of molds.`

Another object of the present invention is an article of manufacturecomprising a runner tile for use in casting horizontal steel ingots andwherein the runner tile and fountain are integral and formed in suchn'lanner that the fountain extends substan tially to the uppermost inletopening adapted. to lead into the mold matrix.

A still lfurther object of the present invention is the provision of arunner tile for use in casting horizontal steel ingots, which tilecomprises an earthen product preferably of porous texture and adapted tohave large heat absorbing capacity whereby the runner tile may be heatedvery hot before being set so as to give off heat during the pouringoperation and prevent Chilling of the steel being poured.

Other and further objects of the present invention will in part beobvious and will in part be pointed out hereinafter by reference to theaccompanying drawings forming a part of this application and whereinlike parts are indicated by like characters throughout the severalfigures thereof.

Realizing that the presentinvention may be embodied in constructionsother than those speciiically shown and described it is desired that thedisclosure herewith shall be considered as illustrative and not in thelimiting` sense. i

Figure l vof the drawings illustrates a horizontal `section through atwo-part mold having a vertical separation plane with the view taken onthe separation plane and showing the runner tilel in section.

f Figure 2 is a view illustrating the pouring` action. j

Figure 3 is a view illustrating shrinkage after the ingot is cold andshowing the shrinkage exaggerated to more clearly illustrate the same.

Figure 4 is a cross section of the mold at one end of the mold andthrough the ruimer' tile recess on line 4 4- Figure l with the runnertile of the mold.

Figure 5 is a cross-section on line 5 5 Figure 1.

Figure 6 is a cross-section of the runner tile.

Figure 7 is a perspective view of the runner tile shown in Figure G.

The presentinvention relates more specially to the production of ingotsfrom dead melted or piping7 steel, such as steel from which the freegases have been largely eliminated and which pours without bubbling orboiling the usual action ofordinary7 or wild steel.. Alloy or highcarbon steels which are usually used forspecialV purposes, for example,high speedv toolsteel, rail, or the like, are usually dead meltedsteels. Such steels may comprise alloys of titanium, vanadium, chromium,tungsten, nick el, combined carbon etc.- This type of steel usuallypours dead17 and when made into ingots has a considerable tendency topipe. Becauseof the special purposes for which such steel is used anyport-ion of the ingot which has pipes mustbe scrapped. .it is customaryin the product-ionof commercial shapes fromsteel of this type, for eX-ample, high speed tool steel to subject the ingots to elaborateprocesses of manufacture todetermine and eliminate these troublesomepipes. Heretofore it has been customary to castY small vertical ingotsfrom tllstype of steel; These ingots are usually cropped in rough tosuch a point as the operator believes will eliminate the majority of thepipes. lngots of this steel are usuall); subjected to processes ofannealing, ham-v mering', pickling, grinding, chipping etc., to vkuetridof pipesfv For example, an ingot of high speed tool steel will be tirstannealed; thenv coggethhannnered. or. rolled into `an Velongated form,of general `redtangular shape; then the seams are `ground out. Thebloom thus formed is pickled with acid, then cropped. if any piges showthe bloom is again cropped. This operationis continued until allevidences of pipes disappear. The bloom or billet4 is then annealedagain and is then rolled .or shaped intothe iinal form, usiuillyv a.bar, whiclris again inspected, annealed and defects cut out, andthe.remaining portion is ready for the market.Yy Often times Vdefects in theoriginal ingot show. upin the. final shape so that aularge portion ofthe final form even may be cropped and discarded as scrap. Vlfhis .typeof steel pipeszso. badly that; in the average run of ingots only arelatively small percentage. isinanufactured into final product, andarrelatively large. percentage is tffouzn aside as scrap. rlhis verygreatly iii-reves the cost of producingfsuch steel.

rlhe presentinvention overcomesithe olifliculties of the known art andVproduces what is known in the art as a perfect ingot77 of whichsubstantially all portions thereof may be manufactured into tinishei'lproduct Preferably this invention is carried out in inclined horizontalchill molds with runner tiles at one end thereof. These tiles preferablyare arranged to produce vertical agitation in the steel in the moldduring pouring and this may be accomplished by a plurality of openings ithe runner tile. lVhere cold runner tiles are used in casting this typeof steel the ingot may appear substantially solid but there is aliability of a small pipe leading from the upper opening into the ingotdownwardly at an angle about double the angle of inclination of the axisof the mold. This liability is completely overcome by heating the runnertile and supply ing su'iiicicnt fresh steel to follow up and lill alltendencies to cavitate, It is also desirable that the runner tilehavethe fountain integral with the body of the tile with the funnelopening-of the fountain leading substantially to the upper inlet openingin the body ofthe tile and with the lower inlet opening in the-runnertile of less diameter than the upper opening. When the tile is soconstructed substantiallyl the same amount of steel enters the moldmatrix from each openingduing pouring. This insures the steel enteringthrough the lower opening spurting into` the mold with considerableforce and velocity while the steel entering through the upper openingWill fall downwardly upon the lower stream, `thereby producing achurning action which Will continue while the mold is rapidly beingfilled. Since the mold is a chill mold they steel farthest from theinlet cools, first and the cooling action progresses from the remote endtoward the inlet opening so that the portion of the ingot against theWide hot runner is. last to freeze. Consequently the freezing orshrinking steel is continually fed on the insidev or corev portion byyliquid or molten steel, up to the final instant of freezing at whichtime the last shrinkage would occur in thev runner itself and the entireingot in the mold is solidnon-segregated steel.

Referringnow to .the drawings the mold may comprise a. pair ofmoldmembers l and 2 which are preferably vseparated on a vertical plane ofseparation and With relatively heavy heat absorbing Walls 4 on all sidesofthe mold matrix The top. and bottom edges of the mold members may beprovided: with clamping lugs-6 over which C-clamps '.are adapted to bedriven in order to. hold the mold members together during thepouringoperation. The mold members are provided at onev end with recesses 8 and9 which extend at rightangles across one end of the mold matrixY andwhich are of a combined width substantially that of the cross-section ofthe matrix. These recesses are adapted to receive a suitable runner tile10. This runner tile is preferably a combined runner tile and fountainand is provided with a body portion 11 and a fountain portion 12. Thebody portion is provided with a vertical conduit 1st which terminates ina lower inlet opening 15 and leads upwardly to the funnel 16 of thefountain. This funnel preferably extends downwardly into the bodyportion of the runner sufficiently so that the upper inlet opening 17 issubstantially within the lower end of the fountain whereby hot steel iscontinually fed to the upper. opening without danger of the conduitbeing choked at this point. Preferably the openings 15 and 17 are soproportioned as to cross-sec tional area that the steel issuing from thelower opening will be substantially the same volume per unit of time asis the steel issuing from the upper opening. Y When the fountain is keptlilled with steel, obviously the pressure at the lower opening isgreater than at the upper opening, therefore during the same intervalmore steel will issue upper opening, unless the areas are respectivelyproportioned to counterbalance the pressure conditions. The ends of themold members may be provided with crane knobs 18 to facilitate thelifting of the mold members and the bottoms of the mold members may beprovided with suitable legs 19 and 20 to maintain the axis of the matrixslightly inclined to the horizontal, with the inclination toward the gasoutlet in the mold body.

lFigure 2 illustrates by means of arrows the churning or stirring actionwhich occurs due to the arrangement of the pouring openings, and arrowsA illustrate the substantially horizontal direction of the steelspurting from the lower opening 15, whereas the arrows B illustrate thedownwardly direction of the steel issuing from the upper opening 17 andthe arrows C indicate the swirling or mixing action in a verticaldirection which occurs in the steel in the mold during the pouringoperation. This action eEectively prevents segregation. Preferably a gasoutlet opening 21 is provided between the mold body and the runner tileadjacent the fountain portion of the tile.4 This facilitates escape ofgases from the mold during pouring.

Referring more specially to Figure 3 which shows the conditionimmediately after freezing and which illustrates the man-ner in whichthe ingot shrinks in the mold, it will be noted that in view of the factthat the end farthest from the runner, cools first, the majority ofshrinkage appears to be4 at this end and the space as at D is formedbetween the end ofthe ingot and the mold wall. A wedge shaped space ,Eis also formed between the upper side walls of the mold and tile isthen` set in the recesses in the end of the mold body and the steel ispoured as quickly as possible after the setting of the hot runner sothat the mold is filled with molten steel before the runner `has cooledto any appreciable extent. As the steel enters the matrix the churningaction specified occurs and there iszno liability of the constituents ofthe alloy segregating. The mold is filled as quickly as possible and thechilling action beginning at the far end of the mold proceeds toward thehot runner tilek which continues to feed'molten steel as is required totill any cavities tending to form due to shrinkage. The final result iswhat is known in the art as a perfect ingot which is adapted to befabricated as an entirety into commercial forms.

Having thus described my invention, what I claim is: f t

1. The method of n'ianufacturing ingots from dead melted steel in ahorizontal covered mold matrix, comprising positioning a preheated walladjacent one end of the mold matrix and introducing molten steel intothe mold matrix through an opening inthe hot wall and in sufficientvolume to quickly lill .the matrix before the hot wall is cooled wall insuflicient volume to quickly iill the matrix beforethe hot wall iscooled to an appreciable extent.

3. The method of manufacturing in chill molds ingots from dead meltedsteel, comprising positioning a hot vertical wall to comprise a verticalend of the mold matrix and introducing molten steel into the mold matrixthrough an opening in the hot wall and in sufficient volume to quicklyfill lthe matrix before the hot wall is cooled to an appreciable extentwhile chilling the remaining sides of the ingot.

4. The method of casting horizontal ingots from dead melted steel,comprising positioning a hot wall adjacent the inlet of the steel to themold cavity, chilling all other portions of the mold cavity, and causingfreezing of the steel to progress from the portion of steel farthestfrom the inlet to-` ward the inlet while the said wall 'is maintainedhot.

liti

The method ot' casting horizontal ingots from dead melted steel,comprising utilizing a hot vertical wall as the inlet for the steel tothe mold cavity, causing the molten steel to enter the mold in ahorizontal direction and to have eddy currents in a vertical direction,chilling all other p0rlions ot' the mold cavity, and causing freezing ofthe steel to progress from the p0rtion of steel farthest from the inlettoward the inlet while the said vertical Wall is maintained hot.

G. The method of cast-ing horizontal ingots from dead melted steel whichcomprises utilizing` a completely covered chill mold, inclining the moldto the horizontal, maintaining a hot Wall adjacent the high end of thomold matrix, and introducing the steel into the mold matrix adjacent thehot Wall.

7. rfhe method of casting steel ingots in a covered chill mold, `whichcomprises positioning a hot runner tile to iorm substantially onevert-ical Wall of the mold matrix and introducing the steel into thematrix through said hot runner tile.

8. The method of casting steel ingots which comprises preheating arunner tile adjacent one Wall of a horizontal closed chill mold andintroducing a plurality of horizontal streams of steel into the` matrixthrough said hot runner tile.

9. The method of casting steel ingots in a cold covered horizontal chillmold, which comprises 'positioning a highly heatedV runner tilevertically at one end of said mold in such manner that the runner tilecomprises substantially the end Wall of said mold and illing said moldfrom said hot runner tile through openings to cause a mixing action ofthe steel as it fills the mold matrix.

10. The method of casting steel ingots in a 'cold covered chill mold,which comprises positioning a highly heated runner tile at one end 'ofsaid mold in such manner that the runner tile comprises substantiallythe end Wall of said mold, and iilling said mold from said hot runnertile through openings having horizontal axes one over the other to causea mixing action of the steel as it fills the mold.

ll. The method of casting steel ingots in a cold covered chill mold,which comprises positioning a highly heated runner tile at one end otsaid mold in such manner that the runne1 'tile comprises substantiallythe end wall of said mold and illinof said mold from said hot runnertile, and maintaining a vertical mixing action in the steel in the molduntil the matrix is illed.

l2; The method ol. casting a steel ing-'ot which comprises casting theingot in a horizontal. full chilled mold, utilizing a heated 'inlet'conduit to prevent the supply stream olr molten steel from freezing,causing agitation in the steel to prevent segregation during pouring,then causing the stoel to freeze as soon as possible after the mold isfilled.

The method oi casting a steel ingot which comprises casting the ingot ina hori zontal full chilled. mold, utilizing a heated inlet conduit toprevent the supply stream of molten steel irom freezing, causingagitation in the steel to prevent segrcgat. ing` pouring, then causingthe steel to as soon as possible after the mold is lilled with the heatgradient runningl tovvard the hot conduit so that the steel in theconduit is last to solidify.

lil. rEhe method ot casting a steel iugot which coniprises casting theingot in an inclined horizontal full chilled mold, utilizingv a heatedinlet conduit to prevent the supply stream of molten steel fromfreezing, pouring the steel into one end of the meld matrix, causingagitation in the steel in the matrix to prevent segregation duringpouring, then causing the steel to freeze as soon as possible after themold is filled.

l5. The method oit casting a steel ingot which comprises castingthe-ingot in a horizontal full chilled mold, utilizing a heated inletconduit to prevent the supply stream of molten steel :trom freezing,causing agitation in the steel to prevent segregation during pouring,causing mold gases to issue from the highest portion of the matrix, then`causing the steel to freeze as soon as possible after the mold isfilled.

16. The method of casting a steel ingot Which comprises casting theingot in an inclined horizontal full chilled mold, utilizing a heatedinlet conduit to prevent the supply stream of molten steel fromfreezing, pouring the steel into one end oi the mold matrix, causingagitation in the steel in the matrix to prevent segregation duringpouring, causing mold gases to issue irom the highest. portion of thematrix, then causing the steel to freeze as soon as possible after themold is lled With the heat `gradient running toward the hot conduit sothat the steel in the conduit is last to solidify.

17. The method of casting steel ingots which comprises heating a Wall ofthe mold matrix, filling the mold matrix oy introducing molten steeladjacent said Wall thereby lilling the 'mold matrix by convergingstreams of steel, quickly chilling the steel in the matrix When thematrix is full while supplying molten steel through the hot wall as thesteel in the mold freezes,

18. The method of casting steel ingots Which comprises heating a Wall otthe mold matrix, filling the mold matrix by introdueing` molten steeladjacent said Wall thereby lilling the mold matrix by a plurality ofconverging streams of steel, quickly chilling the steel in the matrixwhen 'l (Il) the matrix is full and causing the temperature gradient torun towardthe hot Wall While supplying molten steel through the hot Wallas the steel in the mold freezes.

19. The method of casting steel ingots which comprises heating a Wall ofmold matrix, filling the mold matrix by introducing molten steeladjacent said Wall thereby iilling the mold matrix by horizontallydirected converging streams issuing through the hot wall, at the highestpart of the matrix, quickly chilling the steel in the matrix when thematrix is full While supplying molten steel through the hot Wall as thesteel in the mold freezes.

20. The method of casting the metallic ingot which comprises preheatingan end wall of a horizontal closed chill mold, and filling the moldmatrix With molten metal in substantially horizontal streams from thepreheated end before the latterl has cooled.

2l. The method of casting a metallic ingot which consists in preheatinga heatretaining wall forming the major portion of an end of a horizontalcovered mold matrix and then introducing the molten metal adjacent saidWall to fill the matrix before the wall has cooled.

22. rlhe method of casting a metallic ingot which consists in preheatinga heat retaining Wall forming an end of a horizontal covered mold matrixand then introducing the molten metal throl'lgh said Wall in convergingstreams to fill the matrix before the Wall has cooled.

23. The method of casting a metallic ingot which consists in preheatinga heatretaining Wall forming a major portion of an end of a horizontalcovered mold matrix, and then introducing the molten metal through saidWall With a mixing action to fill the matrix before the Wall has cooled.

2l. The method of casting a metallic ingot lwhich consists in preheatinga heatretaining wall forming an end of a horizon- Val covered moldmatrix and then introducing the molten metal adjacent said Wall With amixing action to fill the matrix before the wall has cooled to anappreciable extent.

25. The method of casting metallic ingots which consists in preheating aheatretaining Wall at the inlet end of a horizonorifices in thepreheated end Wall to cause a mixing action Within the mold and chillingthe top, bottom, sides and the end of the confined metal While the headend is in relatively molten condition.

27. The method of casting horizontal steel ingots, Which comprisespreheating an end Wall of a horizontal closed chill mold and filling themold with molten metal through the preheated end thereof before thelatter has cooled materially.

28. The method of casting horizontal ingots which comprises preheating aheat retaining wall in a horizontal covered mold, introducing moltenmetal adjacent said Wall, mixing the metal Within the mold and delayingthe chilling of the ingot at the entrance end of the mold until afterall of the remaining surfaces have been chilled.

29.' The method of casting horizontal ingots which comprises preheatingthe runner tile at one end of a horizontal chill mold and filling themold matrix through said runnerl tile before said tile has cooledappreciably.

30. The method of casting ingots in a horizontal covered mold matrix,Which comprises placing a hot Wall adjacent one end of the horizontalmold and introducing molten steel into the mold matrix adjacent the hotWall to fill the matrix-before the hot Wall cools to an appreciableextent.

3l. The method of casting ingots in a horizontal covered mold matrixWhich comprises mounting a hot member adjacent one end of the moldmatrix and introducing molten metal into the mold matrix adjacent thehot member in sufcient volume to quickly lill the matrix before the hotmember is cooled to an appreciable extent.

i EDl/VARD H. WILLIAMS.

